Method of making surface-covering articles



May 12, 1953 z. w. MANN METHOD oF MAKING suRFAcE-covERING ARTICLES FiledJuly e, 195o @NI @l QM, 9m, uw www K QN NN mm, NN NW V AV LW fd, .,H....0. l J.. ..."1 fw, 7111.. fwn... n. x. l

. 1N VEN TOR.

ZeZz/ermZ/J.

Patented May 12, :A1953 l l UNITED STATES PATENT OFFICE l 'f 1 fy2332;,43'0 d I i t METHD OF MAKING SURFACE-COVERING d ARTICLES vZeh-.fern W. Mann; Chicagof'lll.; assignor'to The Meyercord Co.,Chicago,l Ill., a corporation of Illinois Application July s, 195o,serial No, 172,*21'7v 1 f v'This' invention relates to a process ormethod for 'the manufacture of surface-covering articles such as walltiles, decorative plaques for advertising or display purposes, and thelike. o j

In my copending application Ser.v No. 66,796 lfiled December 22, 1,948,`I haveidescribed and claimed a .novel surface-covering article in theform of a Wall tile or the lke'which can b e quickly vand easilyinstalled by the average person ywithf out the need for special skill orexperience and without the necessity O f utilizing a separate cementormastic." n d l The Wall tile unit or similar surface-covering articledescribed and claimed in my aforementioned prior application comprises aAlaminar structure in which the outermostlayerjis agen-4 erally fiat,semi-rigid, surface-covering element such as a'plastic tile; dDisposed'on the inner surface of this element isarelatively thickstratum or layer of a normally tacky `mastic'or pressuresensitiveadhesivel material adapted tov permanently bond4 the tile to a surface.A removable sealing or protective sheet is disposed 'over .the exposedsurface of the adhesive layer tofprotect the same prior to applica-tionof the tile to' a Surf l face. The tile element' is preferablyformed/with inturned'peripheral lips for retaining thev adhesivelayer'on the tile and to permit sealing engage,- lment of thevprotective sheet with thev edges nof the tile element.r Also, theprotective orsealing "sheet-is preferably in the form of a decalcoinaniabacking paper having a Water solublejgum' or 'adhesive lcoating in orderto permit the' sealing sheet to be readily released from vthe tileAmerely by wetting. Upon removal of the protective sheet the` exposed,adhesive layer is pressed firmly against the wall or other surface in,order to secure the'tile thereon. *y A primary. object of the presentinvention is to provide a novel process lfor manufacturing sur,-'face-covering articles of the foregoing 'type in*- `c1ud`ing 'Walltiles, decorative or display plaques, :and -the like. n

A further object of my invention is to provide a novel method formanufacturing surfacescover- .f

ing articles of the type described which is simple and economical inpractice, which doesvnot'require the use of compl-ex or specialmachinery, and

covering articles of the type described.r n n t f v-Anotherobject of theinvention is lto provide'- a 4 Claims.` (Cl. 154-118) Y 2 novel methodfor applying a pressure-sensitive adhesiveand aprotective sheet tosurface-covering "or facing elements such as wall tile and the like.

Still another object of the invention is to provide a novelgcontinuousmethod for the production lof surface-covering articles of the typedescribed which, although involving certain manual operations, does notrequire any substantial de'- gree of Contact by the operators with thesticky adhesive material.` y ,Y a

Other objects and advantages ofthe invention will become apparent fromthe subsequent detailed description taken in conjunction with theaccompanying drawing wherein:v t K *d yFigi isak fragmentaryelevationalview of one form of continuous apparatus forpracticing rny invention: fo Fig; 2 ispan ,enlarged fragmentary sectional view takensubstantially'along the line 2-2 of Fig. 1 and Vshowing-(thesurface-covering article at an intermediate stage in the process ofmanufacture; Fig. 3 ris anenlargecl fragmentary sectional view takensubstantially along the line 3-3 of Fig'. 1 and showing thesurface-covering article at a'later stage in the; process; and FigQl isa fragmentary'top plan view of a por- .tionof theapparatus shown ingFig. l.

--Bie1ly,V the process ofv my invention Iinvolves 4applying a layer ofadhesive material of: suitable thickness to a sheet ofprotective'material, Asuch as decalcomania backing paper, andsubsequently v-'pressing a tile or other similar surface-covering"element into the adhesive-coated side of the sheet.

A sjwillf appear hereinafter, I prefer to employ a roller-coatingtechnique for coating a continuous strip of the` protective sheetmaterial and then "successively pressing a plurality of tile elementsinto theadhesive-coatedside of the moving strip. -*After thesurface-covering elements have'been pressed into 'position the`striplmay be cut -or otherwise .severed'between adjacent vsurface-*coveringelem-ents in order toform completed units lof thendesired size.

Various attempts were made to produce surface',-

'covering articles of the type here involvedV by ylilling individualtileV elements with the required amount of adhesivel and subsequentlyapplying protectiveisheets to [the adhesive-filled tiles.

Such techniques were found to be slow, cumberf some', andgenerallyunsatisfactory in that they i articles',

"HoWevenIv'ha/ve found that by first applying the adhesive to theprotective sheet material and then covering the adhesive with the tileor other surface-covering element, I am able to assemble the articlesrapidly and with a minimum of inconvenience. Thus, a sheet ofdecalcoinania paper or the like may be provided with a quantity ofadhesive by any suitable technique, e. g. .by spreading the adhesivewith a knife .or spatula, by squeegeeing the adhesive through a stencilto provide an adhesive layer of predetermined size and contour, byscreen printing, by nozzle-type dispensers, etc. Following theapplication of the adhesive, a tile element or the like is then pressedinto engagement With the adhesive and the protective sheet to form theassembled article. ,As hereinafter explained, it is desirable to providea plurality of grooves or channels in the outer surface of the adhesivelayer in order to permit `the escape of air during pressing of the tileelement into place.

,Although the present method may .be used .in batchwisefas'hion forassembling a single surfacecovering article at a time, the method isparticularly adapted to continuous operation for rthe production of aVplurality voi articles .in a unitary processA llhe subsequent detaileddescription of the invention relates to such a continuous .operation butit will be understood that the basic sequence of steps is not limited tocontinuous operation Referring now to the drawing, .the arrangement ofapparatuswhich is shown more or less diagrammatically l has been foundto be particularly advantageous in practicing my invention. A roll li ofprotective sheet material is .carried `on a rotatablebar or shaft l2from which the sheet material .unWinds and .is fed outwardly during theprocess by suitable` roll- `driving means (not shown). This sheetmaterial preferably comprises decalcomania backing paper having appliedto one .side thereof a releasable lm.e. g. a .coatingof a water soluble.gum or adhesive such as 4dextrin. A tank .I3 having electric heatingelements .I4 at the lbottom thereof is ,provided for maintaining aheated supply of a normally tacky pressure-sensitive adhesive materialI5. A coating roller l1 is mounted adjacent the top of the tank i3 .forYpicking up and transferring the adhesive material [.6 to the backingpaper Il.

From the roll H the protective sheet material extends in the form of .anelongated strip I8 over a plurality of idling and tension-.controllingrollers, as indicated at 4151. and then passes into A,contact Vwith .thevcoating roller H. Fig. l, the passage .of thestrip .i8 in contact withthe coating roller Il causes .a layer 2| of the adhesive it to adhere tothe strip, the adhesive being applied to the gum-coated side when theprotective sheet material comprises decalcomania paper. It will beunderstood that for purposes ofclarity the relative thickness of theadhesive layer 2l shown inFi-g. 1 is exaggerated. The adhesive-coatedstrip I3 after contactv with the coating roller il passes overa pulleyor roller 22 .and then moves horizontally in .the opposite direction.

Disposed adjacent the coating machinery is an elongated bed or .table 23having .a pair of spaced rolls .Z4 and 25 mounted `at the opposite `endsthereof and extending into complementary open,- ings it in the bed 23..An endless conveyor .belt 2'! is provided between the rolls .2li and 25with the upper half of the belt extending through the openings .2B andbeing supported flatwise on the As .shown vin bed 23. The roll 25 isconnected to a suitable driving mechanism, shown only fragmentarily at28, for operating the belt 2i. rlhe elongated strip is having theadhesive coating 2i at its upper surface extends over the upper half ofthe conveyor belt 2'! which is supported by the bed 23 and the .strip i8is thereby continuously moved or :fed to the left, as viewed in Fig. 1.As the coated paper strip is fed onto the bed 23, the tile elements,indicated at 29, are then placed manually against the adhesive layer 2iwith only a slight amount of pressure sufficient to depress theperipheral rim portion or lips of the tiles 29 into the adhesive layer2i. The adhesive-coated strip the til-es 29 positioned thereon thenpasses beneath ra pressure-applying means comprising in this case apressure roller 3| journaled in il-shaped 'grooves 32m supporting blocks33 ateach :side of the table. The relative height of the roller 3| abovethe belt 2l and the underlying hed 2.3` is adjusted so that the weightof the roller .3i will exert suflicient pressure on the upper surfacesof the tiles 2.9 to firmly press the latter into Iinal position on thestrip i8 with the rim portions `of the tiles 2'9 in engagement with thepaper strip i8. As seen .clearly in Fig. l .at the right of the roller31 the tiles `529 extend only slightly into the ladhesive stratum 2lprior to contact .with the pressure roller .3 l, but after passagebeneath ,the roller 3l the tiles 2.9 are pressed completely` into thegadhesive layer -as indicated at the left of the roller 3l in Fig. 1.

Although, previously explained, other techniques may be employed forcoating the strip I8 with .the adhesive material I, .I have found thatthe roller .coating technique described herein is particularlydesirable. With proper regulation of thefconsistency or viscosity of theadhesive Ina- .terial -l inthe tank 1.3:, the layer 2l ofpressuresensitive adhesive is `.applied to the strip I8 with acharacteristic grooved .formation comprising a plurality oftransversely-.spaced longitudinally- .extending ridges .or .elongatedhumps which project upwardly from the main body of .the adhesivestratum. This phenomenon Ais. illustrated in Fig. 2 which. is anenlarged cross. sectional View through the webr or strip .I8 las .thelatter leaves thecoating roller I1, `the .relative thicknesses of thevarious layers being exaggerated for clarity. .Thus1 in Fig. 2 thestrip--l 8 is shown as comprising a .paper backing layer-.34 having` a watersoluble gum coating .3.5, and the` pressure-sensitive adhesive stratum2i extends asy a continuous unbroken/.coating .over the gum-coatedsurface .of the strip .in .a width sufcient t-o be covered subsequently.by the tiles .2.9. The adhesive stratum A22| is formed, with arelatively :dat base portion, indicated at 36, and a plurality oftransversely spaced .ridges or humps .3i which extend along the lengthyoi .the strip. Apparently, this ridge formation takes place as a resultof par-tial adherence .0f the `adhesive material It `to the coatingroller l1 as the strip i8 moves away from the coating roller.

For reasons hereinafter discussed, .the yridges 3'! in .the adhesivelayer 2 i .afford .definite advantages both .during the manufacture .ofthe surface-covering ,articles .and during their ultimate use. However,in order to insure this desirable ridge formation it is necessary toregulate the temperature .of the body of rpressuie-.sensitive adhesiveI6 in the tank I3 whereby to provide the proper viscosity in .theadhesive yfor obtaining ridge formation during .the roller-coatingoperation and alsothe proper degree of thickness of the layer.

octy1 pneno1' "The exact temprature in any given caserwillf'o'fcourse',depend on the composition and properties of the particularadhesive material being.. em-

ployed. -In general, the adhesive is too hot its viscosity 'orconsistency is too thin with the ff result that the adhesive is runnyand ridge formation is not realized during transfer ofthe 'adhesive fromthe roller I1 to the strip I8 orrany hesive is too low its viscosity orconsistency is too thick resulting in uneven and stringy application ofthe adhesive to the strip I8 and in a thicker layer than is required for the tiles. y

For purposes of illustration, it has been foun that rva particularlysatisfactory pressure-sensitive adhesive comprises a mixture ofpolyester and polyamide type resins, ethyl cellulose, atemperature-resistant filler and, if desired, a'p-lasticizer andasuitable pigment. More specifically, the following adhesive formula hasbeen used with a roller coating apparatus `of the type herein describedwith excellent results:

Wt. per cent .'Iriethylene glycol ester of hydrogenated rosin(Staybellite Ester #3) 56.5 0.1

Ethyl cellulose 5.3

Polyamide resin comprising dimerized and trimerized unsaturated acids ofvegetable oils with ethylene diamine (Polyamide 93) Finely dividedasbestos (Asbestine) 31.0 Titanium dioxide 1.6

With :the above formula a coating temperature of from about 220 F. toabout 225 F. results in the gum-coated paper strip I8 at suchrelatively` elevated temperatures does not impair the water soluble filmor gum and the film retains its releasable qualities to permit removalof the sheet I8 during installation of the articles.

In Fig. 3 the adhesive layer 2l is shown after a tile 29 has beenpressed into nal position therein. Thus, a tile 29 having a flat bodyportion 38 and peripheral lip or rim portions -39 is pressed downwardlyagainst the adhesive layer 2| until the edge of the rim 39 engages orseats against the gum-coated surface of the strip I8. As a result theridges 31 are flattened, as indicated at 4I, by contact with Ithe bodyportion 38 of the tile and a plurality of air pockets in the form ofgrooves or channels 42 are retained between the flattened peaks orridges. It will be understood that the total height of the ridges 31above the paper strip I8 is slightly greater than the internal height ofthe rim 39 in lorder to obtain the flattening action of the body of thetile against the ridges 31 and thereby insure that the ridges 0fadhesive will ble of the same internal height as the tile rim. However,the total inner height of the rim 39 is greater than the thickness ofthe flat portion 36 of the adhesive layer 2I so that the voids or airchannels 42 are retained after the tiles are in place.

The characteristic formation 0f the ridges 31 and intervening grooves 42in the adhesive layer V2l is a marked advantage duringthe process of-manufacturing the surface-covering articles because of the :reducedamount of adhesive required and because of the lighter weight of thefinal article for sale and shipment. In addition. when the tiles 29 are.pressed downwardly into .the adhesive coating 2I the continuous grooves42 vbetween the ridges 31 permit air to escape from-under `the edges ofthe tiles 29 as the latter are pressed into the adhesive and when therim portions 39 of the tiles are in nal position abutting the strip I8adequate space is still provided` in the enclosed pockets 42 for slightdisplacement or compression of air which may be trapped beneath theindividual tiles. If the adhesive layer 2|.were formed asacontinuouslayerof substantially uniform thickness, it will be seen that a seriousproblemof air displacement and consequent resistance would result duringpressing of the tiles 29 into finalposition. However, by means ofthefridge formation in the adhesive stratum there is sufficient emptyspace unfilled by adhesive to permit air toA escape when .the tile isbeing pressed into position and to permit any ltrapped air to beslightly compressed between the adhesive layer and the superimposed tileelement. The existence .of longitudinal pockets of slightly compressedair on opposite sides of the ridges 31 is also believed toassist inmaintaining the ridge formation during the manufacture of the articlesand during the 4subsequent period prior to use of the articles.

The ridgev formation which exists in the completed article,.as.sh0wn inFig. 3, also affords another advantage in that when the protective sheetI8 having'the water soluble gum coating 35 is removedimmediately priorto use of. the article, the voids `112 permit the adhesive to bedisplaced or shifted within the tile 29 in order that the adhesivestratum may conform readily to surface irregularities in the wall orother surface to which the article is being applied. For example, ifthere is an outward bulge or bump in a wall to which it is desired toapply one of the present surface-covering articles, it will be seen thatwhen the exposed adhesive layer is pressed against the wall over suchbulge, the adhesive 2l within the tile 29 will be displaced slightly toreceive the bulged portion of the wall. 'I'he provision of the pocket 42facilitates and readily permits such displacement of the adhesive duringinstallation of the tile.

In Fig. 4 the general arrangement of the tiles on the continuousadhesive-coated strip I8 is shown in which the tiles 29 have been placedin double rows with the tiles in close contact with each other. It willbe understood that in such an arrangement the width of the adhesivelayer 2I underlying the tiles 29 is approximately the width of two ofthe tile members 29 so that there is an appreciable longitudinal margin43 of coated paper I8 on each side of the row of double tiles in orderto facilitate handling of the same. As the completed tiles are fed offof the work table or bed 23, the-tiles may be four, or any other desirednumber of units, or

individual tile units may be formed by cutting the strip I 8 around allsides of the tiles 29.

I claim:

1. A process for the manufacture of an article of the type describedincluding a tile member having a generally flat body portion with prenformed peripheral lip portions extending outwardly from the plane ofsaid body portion to define an adhesive-receiving recess at one side ofsaid member, said process comprising the steps of coating a sheet ofbacking material with an adhesive layer, and pressing said tile memberinto the adhesive coated side of said sheet until the edges of said lipportions engage said backing sheet whereby said recess is substantiallyfilled with an adhesive layer having a thickness extending from the bodyportion of said tile member substantially to the outer edges ci said lipportions.

"2. A continuous process for the manufacture of articles ci' the typedescribed each-including a tile member having a generally iiat bodyportion with preformed peripheral lip portions extending outwardly fromthe plane 0i said body portion to define an adhesive-receiving recess atone side of said member, said process comprising the steps ofcontinuously coating one side of a strip of backing material with anadhesive layer, placing a plurality of said tile members inpredetermined position on the adhesive coated side of said strip,continuously passing said strip with the tile members in place thereonin contact with a pressure-applying means and thereby pressing the tilemembers into said adhesive layer until the edges of the lip portionsengage said strip whereby the recesses of the tile members are eachsubstantially filled with an adhe- 'sive layer having a thicknessextending from the body of the tile member substantially to the outeredges of the lip portions thereof.

`3. The process of claim 2 further characterized 8 in that after saidtile members have been pressed into the adhesive coated side of saidstrip, the strip is then cut between adjacent tile members tol form -aplurality of separate articles.

4. A Iprocess for the manufacture of an article of the type describedincluding a tile member having a generally flat body portion withpreformed peripheral lip portions extending outwardly from the plane ofsaid body portion to define an adhesive-receiving recess at one side ofsaid member, said yprocess comprising the steps of applying to a sheetof backing material an adhesive layer having a plurality of upstandingridges and intervening depressions, and pressing said tile member intothe adhesive coated side of said sheet until the edges of said lipportions engage said backing ysheet and said ridges `are engaged by thebody portion of said tile member whereby said recess is substantiallylled with an adhesive layerhaving a thickness extending from said bodyportion substantially to the outer edges of said lip portion-s andhaving a plurality of confined air pockets intermediate said ridges.

ZELVERN W. MANN.

References Cited in the iile of this patent UNITED STATES PATENTS NumberName Date 334,300 Sochefsky Jan. 12, 1886 868,157 Bishopric Oct, 15,1907 2,054,448 Russell Sept. 15, 1936 2,135,473 Russell Nov. 1, 19382,145,058 Batcheller Jan. 24, 1939 2,304,787 Avery Dec. 15, 19422,391,539 Avery Dec. 25, 1945

1. A PROCESS FOR THE MANUFACTURE OF AN ARTICLE OF THE TYPE DESCRIBEDINCLUDING A TILE MEMBER HAVING A GENERALLY FLAT BODY PORTION WITHPREFORMED PERIPHERAL LIP PORTIONS EXTENDING OUTWARDLY FROM THE PLANE OFSAID BODY PORTION TO DEFINE AN ADHESIVE-RECEIVING RECESS AT ONE SIDE OFSAID MEMBER, SAID PROCESS COMPRISING THE STEPS OF COATING A SHEET OFBACKING MATERIAL WITH AN ADHESIVE LAYER, AND PRESSING SAID TILE MEMBERINTO THE ADHESIVE COATED SIDE OF SAID SHEET UNTIL THE EDGES OF SAID LIPPORTIONS ENGAGE SAID BACKING SHEET WHEREBY SAID RECESS IS SUBSTANTIALLYFILLED WITH AN ADHESIVE LAYER HAVING A THICKNESS EXTENDING FROM THE BODYPORTION OF SAID TILE MEMBER SUBSTANTIALLY TO THE OUTER EDGES OF SAID LIPPORTIONS.